Container design with built-in overrun meter

ABSTRACT

A container is used in conjunction with ice cream and frozen dessert mixes that do not require the use of ice cream machines. The container acts as a primary or secondary packaging for the powdered mixes and as a foam creation and whisking vessel that contains indicators or markers critical to the proper operation of the mixes, such as target overrun run levels and or whisking target indicators for various types of desserts made using the mixes. The container may contain optional modifications, such as static mixers and homogenizers, that enhance the performance of the mixes and improve the stability and quality of the finished product.

FIELD OF THE INVENTION

The present invention relates to a container for making ice cream and related products and the methods associated thereof.

DESCRIPTION OF THE RELATED ART

Ice cream and related frozen dairy and non-dairy desserts are a major food industry with estimated annual sales approaching 66 billion USD annually. Ice cream is thought to have originated in the time of the ancient Romans. There have been recorded histories of Emperor Nero ordering ice to be brought down from the mountains and then mixed with fruits or honey and consumed as a refreshing dessert. Modern ice cream and similar frozen desserts are reported to have first originated in Arabia or Persia, where craftsmen would mix cream with sugar, yogurt and rose water then chill the resulting mix by adding it to ice.

The Chinese are credited with inventing the first systematic methods to produce where they would add the ingredients into metal pots and place the pots in a mixture of ice and salt which depresses the freezing point of the ice and causes the sweetened mixture inside to freeze more solid.

The first patent for the modern mechanized machine for making ice cream was granted to Nancy Johnson of Philadelphia in 1843. Mrs. Johnson's hand-cranked machine utilized the same principles being used today for home and commercial ice cream manufacturing.

Ice Cream is a foam and a solution and a colloidal suspension all at once. It is basically a foam where the air bubbles are suspended in a solution containing the sweetener and where the walls of the air bubbles are surrounded by fat particles and protein particles which act simultaneously as an emulsifier and a separator between fat particles at the surface of the air bubbles.

In Modern ice cream making where a machine is used there are several steps used including:

-   -   1. Mixing dry ingredients with liquid ingredients (most commonly         milk and Cream)     -   2. Pre-heating     -   3. Homogenization     -   4. Pasteurization     -   5. Cooling     -   6. Storage (Aging)     -   7. Crystallization (Where Aeration takes place and may involve         pressurized air injection)     -   8. Further cooling     -   9. Packaging     -   10. Hardening     -   11. Storage and distribution

This is the general industrial and commercial process. Home ice cream making will usually exclude steps 3,4,8, 9 and 11. In home ice cream making the dry ingredients are mixed with the liquid ingredients (can be heated and aged at this stage) and are added as a solution to an ice cream machine containing a refrigerated drum with a central mixing shaft. As the mixing shaft and/or the drum rotate, the solution beings to freeze (crystallization) due to contact with the internal walls of the refrigerated drum. As the solution rotates and freezes, the mixing shaft scrapes the mixture from the walls and blends back into the center thus entrapping air.

The entrapped air is critical to the properties and qualities of ice cream and associated and similar frozen desserts. the entrapped air gives the ice cream body, firmness and lightness all at once. without air, ice cream and associated frozen desserts would be very dense and very hard (similar to frozen milk) or would require large amounts of fat to maintain their malleability which increases their denseness; this will also affect the nutritional profile of the finished produce per serving. The amount of air in ice cream and associated frozen desserts in measured in % Overrun. % Overrun is generally defined as follows:

% Overrun=(Vol. of ice cream−Vol. of liquid mixture)/Vol. of Liquid mixture×100%

Due to the dramatic impact of overrun on ice cream, its measurement is important. In industrial operations, overrun is quantified either automatically or through volumetric QA measurements using lab equipment.

By their nature, modern ice cream making systems are energy intensive and cumbersome, necessitating large amounts of energy to handle and prepare the ingredients and then more energy in the ice cream machines as these machines try to rapidly and controllably freeze the solution while aerating it before the fat can fully coalesce. Because of this nature and the need to store and prep the ingredients in steps such homogenization, ice cream factories usually will occupy large physical footprints and require significant capital investment which in turn limits entry into the market and inhibits innovation.

The energy consumption associated with ice cream, and related frozen dairy desserts, comes with a heavy environmental impact in terms of pollution. The need to maintain the product in frozen condition throughout its distribution and sales cycle and the use of often non-recyclable containers further adds to environmental impact.

By contrast, home ice cream making machines require relatively less energy overall, require less footprint and have less impact on the environment; they do however produce lower stability products, at lower rates, with significantly less overrun, producing much smaller quantities per unit of time. They also tend to be messy and cumbersome which limits their use as alternatives to industrial Ice cream.

SUMMARY OF THE INVENTION

The problems associated with conventional ice cream making systems and machines has led to the rise of the no-machine-required mixes. By conceptually deconstructing ice cream, stabilizing the components and reincorporating into stable, easily manipulated products, this class of ice cream and frozen dessert mixes seeks to present an alternative method to produce and distribute ice cream and related frozen desserts that would be dramatically cheaper and have a significantly lower environmental impact. In these products, the ice cream process is reconfigured, with a semi-stable foam being created as a first step from mixing dry and liquid ingredients. the Foam requires a target amount of air to be incorporated into it to be stable and prevent fat globules from coming so close together as to form an oily mouth feel. This target varies based on the composition of the liquid used in preparation and is inversely proportional to amount of fat in the liquid; higher fat liquids will require and be able to hold less air while lower fat products will require more and be able to hold more air to be stable. This foam is then frozen using available freezing equipment, the foams created are designed to be stable to the slow freezing rates of home freezers.

Because these products rely so heavily on reaching a target overrun, and because they are primarily targeted at home users who are not technical experts, a novel method to determine target overrun is required. This invention entails a packaging container that acts as a primary or secondary packaging for these no-machine-needed mixes. The powdered no-machine-needed frozen dessert and ice cream mixes are packaged, distributed and sold inside these containers. The container is marked with indicator levels that show the target expansion (overrun) levels for the various types of liquid used in combination with the mixes. The user adds liquid to the container to a marked level. The user then adds the powder mix to the liquid. An aerating device such as a whisk or beaters (manual or automated) is inserted into the container and the mixture is aerated till the mixture reaches the marked overrun target for the liquid used. After the target overrun is reached, the aerating device is removed and the resulting foam is frozen.

The container can have static mixers and/or homogenizers built into the walls of the container to speed up the whisking process and improve the quality of the final product.

Materials used in making the container include but are not limited to:

-   Paper -   Cardboard -   Plastic -   Metal -   Carbon fiber -   Glass -   Polymers -   Wood     Shapes of the container include but are not limited to: -   Cylinder -   Circular cylinder -   Oval cylinder -   Elliptical cylinder -   Elliptical frustum -   Elliptical conical frustum -   Frustum -   Conical Frustum -   Pyramidal Frustum -   Cube -   Square cube -   Rectangular cube -   Hemisphere -   Semi sphere -   Spherical segment -   Spherical cap -   Tubular

Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.

A container for use as a packaging and whisking vessel for no-machine-needed ice cream and frozen desserts is disclosed. The container may be a packaging container. The container includes a sidewall. The container also includes a bottom attached to the sidewall. The container also includes a plurality of markers indicating a plurality of target overrun and whisking targets for a plurality of types of liquids used with no-machine-needed mixes for ice cream and frozen desserts. The plurality of markers corresponds to an amount of foam generated by a mixture of the plurality of types of liquids and dry ingredients for the mixes.

The container may include a lid. The container also may include a divider supported by the sidewall. The container also may include that the divider includes a divider clip to engage a top of the sidewall. The container also may include that the sidewall is a smooth sidewall and the bottom is flat.

A container for use as a packaging and whisking vessel for no-machine-needed ice cream and frozen desserts is disclosed. The container includes a sidewall configured to receive an aerating device. The container also includes a bottom attached to the sidewall. The container also includes a protrusion on the sidewall. The protrusion slopes outwardly and downwards from a top portion of the sidewall to a midpoint then slopes inwardly back to the sidewall. The container also includes a plurality of markers indicating a plurality of target overrun and whisking targets for a plurality of types of liquids used with no-machine-needed mixes for ice cream and frozen desserts. The plurality of markers corresponds to an amount of foam generated by a mixture of the plurality of types of liquids and dry ingredients for the mixes. In some embodiments, the protrusion includes a plurality of indentations.

The container including the protrusion is configured to facilitate mixing of the liquids and mixes, act as a static mixer or a static homogenizer, and reduce the globule/droplet size. The protrusion may have a shape different from that shown including straight, perforated straight, angled, irregular-shaped, wavy, hill-shaped, perforated hill-shaped, ring-shaped, multi-ring-shaped, pumps, needle, and the like.

The entire disclosures of all applications, patents and publications, cited herein and of corresponding U.S. Provisional Application Ser. No. 62/054,392, filed Sep. 24, 2014, are incorporated by reference herein.

From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 represents a container according to the disclosed embodiments.

FIG. 2 represents a cross-sectional view of the container with a divider according to the disclosed embodiments.

FIG. 3 represents a cross-sectional view of the container having static mixers and static homogenizers according to the disclosed embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to specific embodiments of the present invention. Examples of these embodiments are illustrated in the accompanying drawings. While the embodiments will be described in conjunction with the drawings, it will be understood that the following description is not intended to limit the present invention to any one embodiment. On the contrary, the following description is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the appended claims. Numerous specific details are set forth in order to provide a thorough understanding of the present invention.

FIG. 1 depicts a container 100 according to the disclosed embodiments. Container 100 is used as a packaging and whisking vessel for no-machine-needed ice cream and frozen desserts. Container 100 may be in the shape of cup in that it is circular. Container 100 also may have other shapes, such as oval and the like. Container 100 also may be known as a packaging container that holds ice cream and frozen desserts after they have been mixed using the liquids for the ice cream and dessert plus the dry ingredients used in the mixes. Preferably, the mixes are for no-machine-needed desserts.

Container 100 includes an exterior 102. It also includes sidewall 106, which faces the interior of the container. Sidewall 106 may be used in a singular form as container 100 is circular. In other embodiments, more than one sidewall 106 may be used if container 100 has a different shape that configures a plurality of sidewalls, such as a square. Sidewall 106 is attached to bottom 104 of container 100. Sidewall 106 and bottom 104 form cavity 110, which holds the liquid or liquids and mixes to generate the frozen desserts.

A plurality of markers 108 also is included. Markers 108 may be located on exterior 102 or within cavity 110 on sidewall 106. Markers 108 indicate target overrun and whisking targets for the types of liquids used with the mixes. For example, markers 108 are indicator levels that show the target expansion (overrun) levels for the various types of liquid used in combination with the mixes. The user adds liquid to the container to a marked level, shown as mix level in FIG. 1. The user then adds the powder mix to the liquid. An aerating device such as a whisk or beaters (manual or automated) is inserted into cavity 110 of container 100 and the mixture is aerated till the mixture reaches the marked overrun target for the liquid used. After the target overrun is reached, the aerating device is removed and the resulting foam is frozen.

FIG. 2 depicts a cross-sectional view of container 100 with a divider 202 according to the disclosed embodiments. Container 100 includes the features disclosed in FIG. 1. It also includes divider 202. Divider 202 may be inserted into cavity 110 to further divide portions of container 100. For example, container 100 may want to mix and freeze foam for two different ice cream mixes. A divider allows container 100 to keep the mixes and resulting overrun foams separate. Preferably, more than one divider may be used. As shown in FIG. 2, another divider 204 is shown. Divider 204 may include the features of divider 202 disclosed below.

Divider 202 is placed within cavity 110 against sidewall 106. Divider 204 may be placed on the opposite side of container 110 also against sidewall 106. Preferably, divider 202 extends to bottom 104 so that the divider approximates the levels of liquid and mix shown for container 100 by markers 108. The user fills divider 202 to the level indicated by the mix level marker 180 and then aerates the mixture of liquid and dry ingredients to the desired overrun target level. A divider clip 206 may be used to engage a top 207 of sidewall 106. Top 207 may be a lip formed around the circumference of the opening for container 100.

Container 100 may include notch 208 to facilitate interlocking of dividers 202 and 204. Part of the divider 209 may engage notch 208 to keep the divider in place. When dividers 202 and 204 are used, notch 208 and parts 209 of the dividers may keep the items in place so that they do not move around within cavity 110. A gap 210 may be formed to allow two or more dividers to interlock and form multiple chambers within container 100.

FIG. 3 depicts a cross-sectional view of container 100 having protrusions 302 according to the disclosed embodiments. Protrusion 302 may facilitate mixing of the liquid and dry ingredients for the ice cream mixture. It may act as a static mixer or a static homogenizer in that it does not move within container 100. An aerating device may mix or whisk the mixture and the protrusions further cause the mixture to foam. Protrusion 302 also may reduce globule or droplet size. Preferably, a plurality of protrusions may be used in container 100.

Container 100 also includes lid 320 that may be placed on top of sidewall 106 to enclose cavity 110. Lid 320 allows container 100 to then be placed in a freezer or similar location to freeze the mixture and foam within.

Protrusion 302 is located along sidewall 106 facing the interior of container 100. Protrusion 302 includes a first portion that slopes outwardly from sidewall 106, or inwardly to cavity 110. Protrusion 302 also includes a second portion that slopes inwardly to sidewall 106. A midpoint 308 may be used to indicate when the slopes change for protrusion 302. Protrusion 302 may have specified angles for the slopes in order to not damage aerating device 314 when used within cavity 110. Protrusion 302 also may be known as an indentation.

Protrusion 302 also includes holes 310. Holes 310 further facilitate mixing of the liquids and dry ingredients for the ice cream or frozen dessert mix. Referring to FIG. 3, liquid or liquids 312 have been placed into container 110, preferably to the marker indicated by mix level 180. Dry ingredients or mix 314 is added to the contents in container 110. Aerating, or whisking, device 314 is used to mix the combination of liquid(s) 312 and ingredients 314 together. As a result, foam 316 is formed. Foam 316 is formed up to a level desired and indicated by markers 108. Container 100 then may be used as a packaging container in that it can be inserted into a freezer to form foam 316 into the frozen dessert or ice cream.

In some embodiments, container 100 is used as a whisking vessel and intended for use with whisking device 314. Whisking device 314 may be an automated whisk, hand whisk, fork, spoon, beater, stick, and the like. Whisking device 314 moves the contents within container 100, or the fluid mix of liquid 312 and ingredients 314. This action creates a circular flow due to the sidewall or walls of container 100. As the mix flows and impacts protrusions 302 and indentations 310, the mix is agitated such that eddies and vortices are created that mix the contents (liquid 312 and ingredients 314) together. Protrusions 302 and indentations 310 may act similar to mixer blades. This configuration may be considered the reverse of a mixer, where there is a stationary fluid and rotating mixer blades that perform the mixing. Here, the protrusions act as mixing blades, which are stationary, and the contents as the fluid mix are moving.

Protrusions 302 also may be known as static mixers as they are stationary. Holes 310 in protrusions 302 may act as homogenizers. As the mixture is forced through the small holes 310 due to the flow created by whisking device 314, the pools of fat within the mixture are broken down to a larger number of smaller droplets that get dispersed with the solution, or mixture. As these droplets are created, the surface area of fat globules exposed to the solution increases as does the fat surface area available for emulsifiers present in the solution, such as the milk proteins or other emulsifiers, to adsorb onto. Once these emulsifiers adsorb to the surface of these newly created droplets, they resist the re-agglomeration of the fat through electrostatic repulsion and water binding among other forces. This “stabilization” of the fat globules leads to a more homogenized solution that resists separation to produce better feel and texture when consumed.

Referring back to FIG. 1, markers 108 include a 20% overrun marker, a 40% overrun marker, a 60% overrun marker, an 80% overrun marker, a 100% overrun marker, and a 120% overrun marker. Liquid(s) 312 and ingredients 314 are mixed within container 100 to reach one of these marker levels. Also shown in marker 108 are the items corresponding with the different levels. For example, a dense and rich marker may correspond to being below the 20% overrun marker. A gelato marker may correspond to a 40% overrun marker, an industrial confectionary item for use as a commercial product may correspond to an 80% marker, and a light and fluffy marker may correspond to a 120% marker. If one wants to make a gelato frozen dessert, then foam 316 should reach the appropriate overrun marker of about 40%.

Thus, the disclosed embodiments set forth a novel container that facilitates the mixture and production of ice cream and frozen desserts without the use of machines or complicated processes. One may produce desired frozen items in their home and without the need for specialized equipment. The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples. From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. 

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. A container for use as a packaging and whisking vessel for no-machine-needed ice cream and frozen desserts, the container comprising: a sidewall; a bottom attached to the sidewall; and a plurality of markers indicating a plurality of target overrun and whisking targets for a plurality of types of liquids used with no-machine-needed mixes for ice cream and frozen desserts, wherein the plurality of markers corresponds to an amount of foam generated by a mixture of the plurality of types of liquids and dry ingredients for the mixes.
 5. The container of claim 4, wherein the container includes a lid.
 6. The container of claim 4, further comprising a divider supported by the sidewall.
 7. The container of claim 6, wherein the divider includes a divider clip to engage a top of the sidewall.
 8. The container of claim 4, wherein the sidewall is a smooth sidewall and the bottom is flat.
 9. A container for use as a packaging and whisking vessel for no-machine-needed ice cream and frozen desserts, the container comprising: a sidewall configured to receive an aerating device; a bottom attached to the sidewall; a protrusion on the sidewall, wherein the protrusion slopes outwardly and downwards from a top portion of the sidewall to a midpoint then slopes inwardly back to the sidewall; and a plurality of markers indicating a plurality of target overrun and whisking targets for a plurality of types of liquids used with no-machine-needed mixes for ice cream and frozen desserts, wherein the plurality of markers corresponds to an amount of foam generated by a mixture of the plurality of types of liquids and dry ingredients for the mixes.
 10. The container of claim 9, wherein the protrusion includes a plurality of holes.
 11. The container of claim 9, wherein the protrusion is configured to facilitate mixing of the liquids and mixes, act as a static mixer or a static homogenizer, and reduce globule/droplet size.
 12. A container for use as a packaging and whisking vessel for no-machine-needed ice cream and frozen desserts, the container consisting of: a sidewall configured to receive an aerating device; a bottom attached to the sidewall; a protrusion on the sidewall, wherein the protrusion slopes outwardly and downwards from a top portion of the sidewall to a midpoint then slopes inwardly back to the sidewall; and a plurality of markers indicating a plurality of target overrun and whisking targets for a plurality of types of liquids used with no-machine-needed mixes for ice cream and frozen desserts, wherein the plurality of markers corresponds to an amount of foam generated by a mixture of the plurality of types of liquids and dry ingredients for the mixes. 